Diamond modified heat exchangers, steam generators, condensers, radiators and feedwater heaters

ABSTRACT

Diamond has superior strength and heat transfer capability. The efficiency of heat exchangers, steam generators, condensers, radiators and feedwater heaters is increased by using diamond tubes ( 10 ). Heat exchangers are made containing diamond tubes ( 10 ) diamond tube sheets ( 15 ) and diamond baffles ( 40 ). Steam generators are made containing containing diamond tubes ( 10 ) and diamond tube sheets ( 15 ). Radiators are made containing diamond tubes ( 10 ) and diamond fins ( 55 ). Condensers are made containing containing diamond tubes ( 10 ) diamond tube sheets ( 15 ) and diamond fins ( 55 ). Feedwater heaters are made containing diamond tubes ( 10 ) diamond tube sheets ( 15 ) and diamond baffles ( 40 ).

CROSS REFERENCE TO RELATED APPLICATIONS

Not applicable.

BACKGROUND

1. Field of the Invention

This invention relates to heat exchangers, including steam generators, condensers, radiators and feedwater heaters, specifically to the material composition of their tubes, fins and tube sheets.

2. Description of Prior Art

Currently, most heat exchangers, steam generators, condensers, radiators and feedwater heaters use metal tubes to heat or cool fluid. These tubes are normally made of copper, aluminum, stainless steel or an alloy containing these metals. These metals and alloys are used because they have good heat transfer capabilities and can resist corrosion. Some heat exchangers are made from plastics because they need to operate in corrosive environments. Industrial processes and power production facilities utilize many heat exchangers, steam generators, condensers, radiators and feedwater heaters that are subjected to harsh operating conditions and environments. It would be beneficial to create heat exchangers, steam generators, condensers, radiators and feedwater heaters that have superior strength, superior heat transfer capabilities, are able to withstand very high pressures and temperatures and can resist most corrosive conditions seen in industry and power plants.

Diamond is the hardest material known to man at this point. It has a Mohs Hardness of 10. Diamond is acid resistant below 400° C. or 752° F. It also has an excellent thermal conductivity coefficient (around 20 W/m° C.) and it has high thermal diffusivity. This makes it ideally suited for the tubes and certain other components used in heat exchangers, steam generators, condensers, radiators and feedwater heaters. Using a process such as that described in U.S. Pat. No. 7,547,358 by Shapiro it is possible mass produce inexpensive diamond. This diamond can then made into pipes and tubes as explained in U.S. application Ser. No. 12/494,196 by Scorziello. These tubes can then be used in heat exchangers, steam generators, condensers, radiators and feedwater heaters. Diamond sheets can also be made to accommodate these tubes and act as fins, baffles or tube sheets in, radiators, feedwater heaters and condensers. Due to diamond's unique properties heat exchangers using diamond tubes and fins can be smaller and stronger than current heat exchangers.

Blackman et al. put diamond fibers around radiator tubes to increase heat rejection in U.S. Pat. No. 5,150,748. However this hinders cross current flow which is detrimental to heat rejection and is not practical for power generation facilities because the fibers will get fouled and decrease the efficiency of the heat exchanger and therefore the power plant. This can cause unsafe conditions and threaten the safety of the plant workers and the public especially in a nuclear power plant. Pinneo uses diamond to make a heat pipe in U.S. Pat. No. 6,880,624. However heat pipes are closed and don't allow the fluid in them preform work that can be converted to electrical power or other useful work. For example steam must pass through a turbine so it can turn a generator in order to make electricity. The steam then is condensed in the condenser to become condensate that is sent to the steam generator as feedwater. The feedwater is heated by some steam before it enters the steam generators to become steam for the turbines, and the cycle repeats itself. Also some heat exchangers must wait for long periods of time before they are called into service. Some heat exchangers such as emergency core cooling heat exchangers have no fluid to draw on until it is released from a reactor during an accident. Pinneo's heat pipes are well suited for cooling electronics but are not suited for industrial processes or for power production because the heated fluid is locked within the heat pipe.

SUMMARY

In accordance with the present invention heat exchangers, steam generators, condensers, radiators and feedwater heaters contain tubes made from diamond with Mohs Hardness of 10. Radiator fins are also made of diamond to increase efficiency. Tube sheets are made of diamond to accommodate diamond tubes and to increase heat transfer efficiency. Baffles are made of diamond to increase efficiency.

Objects and Advantages

Accordingly, several objects and advantages of the present invention are:

-   -   (a) to provide heat exchangers, steam generators, condensers,         radiators and feedwater heaters with excellent heat transfer         capabilities.     -   (b) to improve the efficiency of industrial processes by using         highly efficient heat exchangers, steam generators, condensers,         radiators and feedwater heaters with diamond tubes.     -   (c) to save fuel during the production of electricity by         increasing the efficiency of heat transfer processes.     -   (d) to reduce the space required to house heat exchangers, steam         generators, condensers and radiators.     -   (e) to increase the safety margin of power plants by increasing         the efficiency of heat transfer processes.

Still further objects and and advantages will become apparent from a consideration of the ensuing description and drawings.

DRAWING FIGURES

FIG. 1 shows a cross section of a typical simplified counter flow shell and tube heat exchanger with diamond components.

FIG. 2 shows a cross section through a typical simplified steam generator with diamond components.

FIG. 3 shows a simplified typical radiator type heat exchanger with diamond components.

FIG. 4 shows a simplified typical condenser with diamond components.

FIG. 5 shows a simplified typical feedwater heater with diamond components.

REFERENCE NUMERALS IN DRAWINGS

-   10—diamond tubes -   15—diamond tube sheets -   20—tube inlet -   25—tube outlet -   30—shell inlet -   35—shell outlet -   40—diamond baffles -   50—shell -   55—diamond fins -   60—cross flow -   62—heated or cooled fluid

DESCRIPTION—FIGS. 1, 2, 3, 4, 5—PREFERRED EMBODIMENT

Those of ordinary skill in the art will realize that the following description of the present invention is illustrative only and not in any way limiting. Other embodiments of the invention will readily suggest themselves to those skilled in the art.

FIG. 1 shows the a cross section through a simplified diamond modified shell and tube heat exchanger (shell and tube heat exchangers are similar to a steam generators). Although there are many types of heat exchangers this figure is used to illustrate what the invention is and should not be limited by it. The tubes are made from diamond 10. The tube sheet 15 is made from diamond. The heat exchanger has a tube inlet 20 and a tube outlet 25. The heat exchanger has a shell inlet 30 and shell outlet 35. The heat exchanger has mixing baffles 40 made of diamond. The heat exchanger has an outer shell 50. The shell 50 is made of a metal alloy.

FIG. 2 shows the a cross section through a simplified diamond modified steam generator. Although there are many types of steam generators this figure is used to illustrate what the invention is and should not be limited by it. This figure shows a once-through heat exchanger. Other steam generators consist of U-tubes. This invention applies to them as well. The tubes are made from diamond 10. The tube sheets 15 are made from diamond. The steam generator has a tube inlet 20 and a tube outlet 25. The steam generator has a shell inlet 30 and shell outlet 35. The steam generator has an outer shell 50 made of a metal alloy.

FIG. 3 shows a simplified radiator type heat exchanger with diamond components (radiator heat exchangers are similar to condensers). The tubes are made from diamond 10. The fins 55 are made from diamond. Fluid travels through the tubes 60. Air travels across 60 the fins 15 and tubes 10.

FIG. 4 shows a simplified typical condenser with diamond components. The tubes are made from diamond 10. The tube sheets 15 are made from diamond. Cool water travels through the tubes 60. Steam travels across 60 the tubes 10. Some condensers have fins (see FIG. 3) to increase efficiency.

FIG. 5 shows a simplified typical feedwater heater with diamond components. A feedwater heater is similar to a steam generator except that instead of making steam it uses steam to heat feedwater. Although there are many types of feedwater heaters this figure is used to illustrate what the invention is and should not be limited by it. Other feedwater heaters consist of U-tubes. This invention applies to them as well. The tubes are made from diamond 10. The tube sheet 15 is made from diamond. The feedwater heater has a tube inlet 20 and a tube outlet 25. The feedwater heater has a shell inlet 30 and shell outlet 35. The feedwater heater has mixing baffles 40 made of diamond. The feedwater heater has an outer shell 50. The shell 50 is made of a metal alloy.

Advantages

From the description above, a number of advantages of my diamond modified heat exchangers, steam generators, condensers, radiators and feedwater heaters become evident:

-   -   (a) Diamond tubes are lighter but stronger than metal pipes.         This allows heat exchangers, steam generators, condensers,         radiators and feedwater heaters to weigh less than current heat         exchangers, steam generators, condensers, radiators and         feedwater heaters.     -   (b) The seismic requirements to support heat exchangers, steam         generators, condensers, radiators and feedwater heaters that are         lighter, will be less thereby reducing the cost of construction         of a power plant.     -   (c) Diamond tubes are well suited for industrial processes.     -   (d) Heat exchangers, steam generators, condensers, radiators and         feedwater heaters containing diamond tubes are more efficient         than current heat exchangers, steam generators, condensers,         radiators and feedwater heaters. Therefore they can be smaller         than current heat exchangers, steam generators, condensers,         radiators and feedwater heaters.     -   (e) Existing power plants can replace their heat exchangers,         steam generators, condensers, radiators and feedwater heaters or         portions thereof with heat exchangers, steam generators,         condensers, radiators and feedwater heaters containing diamond         tubes. Or they can just replace the internal tubes, fins, tube         sheets or baffles with diamond tubes, fins, tube sheets or         baffles. This will allow them to update their power generation         giving them more revenue.     -   (f) Electrical utilities replacing old heat exchangers, steam         generators, condensers and radiators with diamond tube heat         exchangers, steam generators, condensers and radiators can         expect to increase their safety margins because diamond has         excellent heat transfer capabilities. Diamond's thermal         conductivity coefficient is very large.     -   (g) Steam generators made with diamond tubes can increase the         efficiency of an electrical power plant. This will save fuel.     -   (h) Condensers made with diamond tubes can increase the         efficiency of an electrical power plant. This will save fuel.     -   (i) Electrical power plants using safety related heat exchangers         with diamond tubes will increase their safety margins.     -   (j) Heat exchangers, steam generators, condensers and radiators         with diamond tubes will not experience tube failures because         diamond is the strongest material known to man and the tubes can         be designed to never fail. This will reduce maintenance and life         cycle costs.

Operation—FIGS. 1, 2, 3, 4, 5

FIG. 1 shows a diamond modified shell and tube heat exchanger. Typically hot fluid enters the tube inlet 20. It travels through the diamond tubes 10. The diamond tubes 10 are supported in an array by diamond tube sheets 15. The cooled fluid travels out the tube outlet 25. Cooling fluid enters the shell inlet 30. It travels around the diamond baffles 40 and around the diamond tubes 10 removing heat. It exits through the shell outlet 35. The shell 50 is metal to reduce heat gain/loss through the shell 50 which will reduce efficiency.

FIG. 2 shows a diamond modified steam generator. Hot primary water enters the tube inlet 20 and travels through the diamond tubes 10 to the tube outlet 25. Feedwater enters the shell inlet 30 (secondary side) of the steam generator. The feedwater is heated, boiled and turned into steam. Steam exits the shell outlet 35. Diamond tubes 10 are supported by diamond tube sheets 15. The shell 50 is metal to reduce heat loss through the shell 50 which will reduce efficiency.

FIG. 3 shows a simplified diamond modified radiator. Normally heated or cooled fluid 62 travels through the diamond tubes 10. Diamond fins 55 help to transfer heat to/from the fluid to/from the cross flow 60 fluid. Radiators normally have hot fluid flow through the tubes 10. Cool air removes heat by traveling around the tubes and through the fins 55.

FIG. 4 shows a simplified diamond modified condenser. Condensers are similar to radiators except they have cool water 62 traveling through the diamond tubes 10 and steam flowing across 62 the tubes 10. Condensers may also have fins 55 (not shown) to increase efficiency. Tube sheets 15 support the tubes and separate the cold water from the steam and condensate. Diamond tube sheets 15 would increase a condenser's efficiency.

FIG. 5 shows a simplified typical feedwater heater with diamond components. Condensate needs to be heated to increase the efficiency of a power plant. Feedwater enters the feedwater heater tube inlet 20. It travels through the diamond tubes 10. The diamond tubes 10 are supported in an array by diamond tube sheets 15. The heated feedwater travels out the tube outlet 25. Steam is used to heat the feedwater and enters the shell inlet 30. It travels around the diamond baffles 40 and around the diamond tubes 10 heating the feedwater. It exits through the shell outlet 35. The shell 50 is metal to reduce heat loss through the shell 50 which will reduce efficiency. This invention applies to feedwater heaters that contain U-tubes also.

Conclusion, Ramification and Scope

Accordingly the reader will see that diamond tubes, fins, tube sheets and baffles used in heat exchangers, steam generators, condensers, radiators and feedwater heaters are very useful and can increase the efficiency of processes such as power generation. Increasing the efficiency of an industrial process will lead to a reduction of fuel and energy consumption. Diamond components used in heat exchangers, steam generators, condensers, radiators and feedwater heaters can also be used to increase the safety margin of electric power plants. This reduces the health risk to workers and the public.

Although the description above contains many specificities, these should not be construed as limiting the scope of the invention but as merely providing illustrations of some of the presently preferred embodiments of this invention. The invention therefore is not restricted except in the spirit of the appended claims. 

1. A heat exchanger comprising of diamond tubes with Mohs Hardness of
 10. 2. The heat exchanger of claim 1 further comprising: diamond tube sheets with Mohs Hardness of
 10. 3. The heat exchanger of claim 1 further comprising: diamond baffles with Mohs Hardness of
 10. 4. A steam generator comprising of diamond tubes with Mohs Hardness of
 10. 5. The steam generator of claim 4 further comprising: diamond tube sheets with Mohs Hardness of
 10. 6. A condenser comprising of diamond tubes with Mohs Hardness of
 10. 7. The condenser of claim 6 further comprising: diamond tube sheets with Mohs Hardness of
 10. 8. The condenser of claim 6 further comprising: diamond fins with Mohs Hardness of
 10. 9. A radiator comprising of diamond tubes with Mohs Hardness of
 10. 10. The radiator of claim 9 further comprising: diamond fins with Mohs Hardness of
 10. 11. A feedwater heater comprising of diamond tubes with Mohs Hardness of
 10. 12. The feedwater heater of claim 1 further comprising: diamond tube sheets with Mohs Hardness of
 10. 13. The feedwater heater of claim 1 further comprising: diamond baffles with Mohs Hardness of
 10. 